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Selection & Applications Of Power Factor Correction Capacitor For Industrial and Large Commercial Users
Agenda
Power Factor Fundamental The Need for Power Factor Correction Effects of Harmonics: TPF & DPF Correction Alternatives & Capacitor Locations PF Rate, Capacitor Sizing, & ROI Capacitor Applications To Motors Capacitor Switching Equipment Other Application Issues * Steady State VAR Correction * Dynamic VAR Correction Standards & Codes
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Most plant loads are Inductive and require a magnetic field to operate:
The magnetic field is necessary, but produces no useful work The utility must supply the power to produce the magnetic field and the power to produce the useful work: You pay for all of it! These two types of current are the ACTIVE and REACTIVE components
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Mug Capacity = Apparent Power (KVA) Foam = Reactive Power (KVAR) Beer = Real Power (kW) kVA
Apparent Power
Power Factor =
kW
Active Power
Capacitors provide the Foam (KVAR), freeing up Mug Capacity so you dont have to buy a bigger mug and/or so you can pay less for your beer !
Active (Real) Power Total Power Reactive = kW Power (KVAR) kVA = Cosine () = DISPLACEMENT POWER FACTOR
Power Factor
A power factor reading close to 1.0 means that electrical power is being utilized effectively, while a low power factor indicates poor utilization of electrical power.
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IR V ILOAD
IC
KVARC KW KVARL
KW
KVAR (LAG)
KW
KVAR (LEAD)
KW
KVAR (LAG)
KW
KVAR (LEAD)
INDUCTION MOTOR
OVER-EXCITED
SYN. MOTOR
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Power Factor 75-80 76-80 80-85 65-75 65-80 35-60 65-70 75-80 70-80 75-80 60-65 65-70 80-90 40-60 55-65 75-80 60-70 65-80 65-75 60-65
By Operation Air compressor: External motors Hermetic motors Metal working: Arc welding Arc welding with standard capacitors Resistance welding Machining Melting: Arc furnace Inductance furnace 60Hz Stamping: Standard speed High speed Spraying Weaving: Individual drive Multiple drive Brind
Power Factor 75-80 50-80 35-60 40-60 40-60 40-65 75-90 100
60 70 70-75
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1 2
Power Factor Correction Capacitors (PFCC) provide an economical means for improving Energy utilization
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In this example, demand was reduced to 8250 kVA from 10000 kVA.
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Harmonics
Displacement Power Factor
Linear vs Non-Linear
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Computers
Fax Machines
Copiers
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Time vs Frequency
Time Domain
f1 = 60 H z
Frequency Domain
1 0.5 0 1 3 5 7 9 1 1
60 Hz
f1
f3 = 3 x 60hz = 180 hz
+
180 Hz
1 0.5 0 1 3 5 7 9 1 1
f3
f5 = 5 x 60 hz = 300 hz
+
300 Hz
1 0.5 0 1 3 5 7 9 1 1
f5
f7 = 7 x 60 hz = 420 hz
+
420 Hz
1 0.5 0 1 3 5 7 9 1 1
f7
D isto rted Wave = f1 + f3 + f5 + f7
1 0.5
0 1 3 5 7 9 1 1
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I
TDD
2 2
+ I
+ I
1
2 4
+L
100 % =
h
= 2
Ih
100
1
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Harm Coefficient =
Harm coefficient =
1 1 + .92 = .7433
Applying Capacitors:
VFD
M M M M
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Parallel combination of capacitors with motor or transformer can cause resonance condition
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Resonance
The installation of standard capacitors can magnify harmonic currents on the network
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Resonance XL
( XL-Xc )
X L = 2fl
XC =
1 2 fc
fr
XC
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Capacitor Resonance
Resonant Point likely to amplify dominant harmonic (typically 5th)
Magnification of Harmonic Current when Standard Capacitor are Added to the Network
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I<h5>
Z
Ih5
f
A
f1
f3
f5
f7
f9
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Due to PF Adjustment, KW2 > KW1 *Distribution System Charge *Nuclear Decommission Charge *Transition Charge-1 *Transition Charge-2 *Transmission Service Charge *Transmission Cost Recov Factor = (KW2-KW1) x $3.55 / apfa = M1 = ( KW2-KW1) x $0.044/apfa = M2 = (KW2-KW1) x $0.177/ apfa = M3 = (KW2-KW1) x $0.272 / apfa = M4 = (KW2-KW1) x $1.19 / apfa = M5 = (KW2-KW1) x $0.27103 /apfa =M6
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Capacitor Locations
M A B C A
M M M M
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Side Benefit
voltage support Small I2R reduction
Usage
Correcting pf on individual loads such as motors
Disadvantages
Overcompensation (correct past unity) Not to be used on non-linear loads Unable to track minute by minute load changes occurring on non-compensated feeders
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Side Benefit
voltage support Small I2R reduction
Usage
Correcting pf on entire MCCs or substations
Application alert
Not to be used on nonlinear loads
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For sensitive networks Similar to Antiresonant Automatic Capacitor System except solid state switching Reactor tuned to 4.2 or 4.4 Response time < 5 sec Use where NonLinear Loads < 50% of Total Loads.
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L2
L3
De-tuned Inductor
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When Transformer KVA To Cap. KVAR Ratio < 3 Select Anti-Resonant ( Detuned) Auto. Cap. Bank
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RESULTING IN
VOLTAGE FLICKER VOLTAGE SAGS POOR POWER FACTOR INABILITY TO START MOTORS
4 2
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Hybrid Filters
Combination of passive & active technologies
+
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4x300A ACCUSINE
PASSIVE
ACTIVE
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HVC
15000
Vars Leading/Lagging
10
12
14
16
-5000 -10000
Time in cycles
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SOLUTIONS
APPLICATION OF:
HYBRID VAR COMPENSATION (HVC)
RESULTING IN
VOLTAGE FLICKER VOLTAGE SAGS POOR POWER FACTOR INABILITY TO START MOTORS
DYNAMIC VAR INJECTION ON PER CYCLE BASIS PASSIVE/ACTIVE SYSTEM ARRANGEMENT WITH INRUSH OR DE-TUNED REACTORS CUSTOM-ENGINREERED FOR SPECIFIC SITE, NETWORK, LOAD CHARACTERISTIC NEEDS
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> Motor Overload Protection > Re-closure Issue Jogging , Reversing, Inching , Plugging Applications
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Substation
Cos 2= 0.55
Cos 1= 0.89
1818 KVA
1537 KVA
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Capacitor Standards
NEMA CP-1 for Shunt Capacitors UL 810 Standard for Capacitors NFPA 70, National Electrical Code IEEE Standard 399, Power System Analysis ANSI / IEEE Standard 18, Shunt Power Capacitors IEEE Standard 141, Recommended Practice for Electrical Power Distribution for Industrial Plants
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Summary of Benefits:
Since Capacitors supply reactive power, you dont pay the utility for it Depending up on location of Cap. Bank, Line Loss can be reduced. You can calculate the savings
Off-load transformers
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